M.E.

Semester:1 Subject :Advanced Machine Design

Gear Design

Spur Gear Nomenclature

Interference in gears

PROFILE SHIFTED GEARS / Non Standard gears

Interference in smaller number of tooth pinions can be avoided by having unequal addendum, longer addendum for the pinion and shorter for the gear as seen in the earlier figure. These are called profile shifted gears or non-standard gears

Materials for gears

1. Malleable cast iron. 2. Cast Iron 3. Carbon steel 4. Carbon chromium steel 5. Carbon manganese steel 6. Manganese molybdenum steel 7. Chromium molybdenum steel 8. Surface hardened steel 9. Case hardened steel 10. Phosphor bronze castings

Selection of Gear Materials

There are some very critical matters that needs to be given a consideration before selecting a gear material. Allowable bending and hertz stress Wear resistance Impact strength Water and corrosion resistance Manufacturing cost Size Weight Reliability Lubrication requirements No Moisture Absorption Dimensionally Stable Stress-Free structure Environmental and surface temperatureIt has been found that if there is friction the surface temperature of the gear shows a tendency to rise.

Worm and Wheel/Worm Gears

Worm and Wheel/Gear

Rack and Pinion

Harmonic Drive

Feb-2012 1. What is profile correction of gears? Explain S0 and S corrected gears with characteristics of corrected gears. July-2012 1.Discuss the recent advances in gear materials and its heat treatments in detail. 2. What do you mean by power rating of gears? Explain the gear rating as per BIS4460-1967 in detail. Feb-2011 1. Explain corrective gear design. July-2011 1. What do you mean by corrected gearing? In which situation such gears are used? Why? Jan-2010 1. Why the gear profile is corrected? Explain characteristics of corrected gears. 2. Design a pair of CI gear to transmit 12 KW having pinion speed of 200 rpm. The speed reduction is 2:1. Assume face width is three times the circular pitch. The number of teeth on pinion is 24. Take pressure angle is 14.50. The modulus of elasticity for pinion is 0.8 X 105 N/mm2. Errors in manufacturing is not to exceed 0.05 mm. The allowable bending stress for CI is 45 N/mm2. Take elastic stress as 81 N/mm2 and surface endurance limit 280 N/mm2 for gear pair. Check the design for all failures.

What do you mean by power rating of gears? Explain the gear rating as per BIS-4460-1967 in detail.
5.21 GEARING: 5.21.1 Gearing types, Gearing shall be spur, herringbone, helical as specified in the IS 4460, 7504. No split gears or overhung gears shall be used without specific approval of the owner. 5.21.2 Gearing Design: Horsepower ratings for all spur and helical involute gearing shall be based upon American Gear Manufacturers Association or IS 4460 Fundamental Rating Factors and Calculation Methods for Involutes Spur and Helical Gear Teeth. 5.21.3 Allowable Stress (Sac) and (Sat) The allowable stress for contact stress (Sac) and for bending stress (Sat) and material used shall be as listed for Grade I material as per IS 4460. 5.21.4 Dynamic Factors (Cu) and (Ku), The dynamic factors for pitting resistance (Cu) and for bending strength (Ku) shall be as per Paragraph 8.3.2 and 8.3.3 of AGMA 2001 B-88 based on the lowest quality member in the mesh. 5.21.5 Elastic coefficient, (CP),The elastic coefficient (CP) shall be as per IS 4460.

5.21.6 Hardness Ratio Factor (CH), The hardness ratio factor (CH) shall be as per IS 4460. 5.21.7 Service Factors,The service factors (CSF) and (KSF) shall be used as per IS 4460. 5.21.8 Maximum and Minimum Gearing Face width: The gearing face width shall be a maximum of 1.4 times the pinion pitch diameter and a minimum of 3 times the circular pitch. 5.21.9 Gear Design Loading, Hoist gear loading for bending strength and pitting resistance shall be based on the torque required to lift the rated load plus hook block and/or lifting beam. Travel drive gear ratings for bending strength and pitting resistance shall be based on 2 times the 60 minute motor rating for series wound constant potential. D.C drives, and 1.7 times the 60 minute motor rating for A.C motors and adjustable voltage D.C drives without motor field weakening, or wheel slip at maximum wheel load (0.20 friction factor) whichever is lower. Due consideration shall be given to the maximum brake torque which can be applied to the drive.

Quality Function Deployment

Quality function deployment (QFD) is a method to transform user demands into design quality, to deploy the functions forming quality, and to deploy methods for achieving the design quality into subsystems and component parts, and ultimately to specific elements of the manufacturing process., Work in quality assurance and quality control points with function deployment used in value engineering. QFD is designed to help planners focus on characteristics of a new or existing product or service from the viewpoints of market segments, company, or technology-development needs. The technique yields graphs and matrices.

A quality assurance tool for profit and non-profit organizations aimed at locating customer needs and transcending those needs into product/service production stages, ensuring that customer needs are delivered in the end.
QFD helps transform customer needs (the voice of the customer [VOC]) into engineering characteristics (and appropriate test methods) for a product or service, prioritizing each product or service characteristic while simultaneously setting development targets for product or service. Quality Function Deployment (QFD) was developed to bring this personal interface to modern manufacturing and business. In today's industrial society, where the growing distance between producers and users is a concern, QFD links the needs of the customer (end user) with design, development, engineering, manufacturing, and service functions.

THE PROCESS OF QFD

The Four Steps of the QFD process: 1. Product Planning (House of Quality) 2. Product Design (Parts Deployment) 3. Process Design (Process Planning) 4. Production Design (Production Planning)

Concurrent Engineering Defined 1st Definition

The simultaneous performance of product design and process design. Typically, concurrent engineering involves the formation of cross-functional teams. This allows engineers and managers of different disciplines to work together simultaneously in developing product and process design.

Concurrent Engineering Defined 2nd Definition

Concurrent engineering methodologies permit the separate tasks of the product development process to be carried out simultaneously rather than sequentially. Product design, testing, manufacturing and process planning through logistics, for example, are done side-by-side and interactively. Potential problems in fabrication, assembly, support and quality are identified and resolved early in the design process.

Brainstorming
Brainstorm some ideas about Concurrent Engineering

How can this tool be used in your organization?

Nuts and Bolts

Basic Tenets of Concurrent Engineering -Doing things simultaneously -Focusing on the Process -Converting hierarchical organizations into teams. Basic Goals of Concurrent Engineering -Dramatic improvements in time to market and costs. -Improvements to product quality and performance. -Do more with less.

 Management -Good mgmt is vitally important -Encourage communication -Strong mgmt support

How it Works
Three Main Areas to Concurrent Engineering 1) People 2) Process 3) Technology Area 1: People -Formation of teams -Training Area 2: Process -Changes in your processes -Be open to change Area 3: Technology -CAD/CAM -Software,Hardware and Networking

 Auto frettage is a metal fabrication technique in which a pressure vessel is subjected to enormous pressure, causing internal portions of the part to yield and resulting in internal compressive residual stresses. The goal of auto frettage is to increase the durability of the final product. Inducing residual compressive stresses into materials can also increase their resistance to stress corrosion cracking; The technique is commonly used in manufacturing highpressure pump cylinders, battleship and tank cannon barrels, and fuel injection systems for diesel engines. While some work hardening will occur, that is not the primary mechanism of strengthening. The elasticity of the barrel can be tested by applying internal pressure once more, but this time care is taken to ensure that the inner layers are not stretched beyond their new elastic limit.

Autofrettage

 When autofrettage is used for strengthening cannon barrels, the barrel is bored to a slightly undersized inside diameter, and then a slightly oversized die is pushed through the barrel. The amount of initial underbore and size of the die are calculated to strain the material past its elastic limit into plastic deformation, sufficiently far that the final strained diameter is the final desired bore.

Rotating Disc
Rotating discs work mostly at high angular velocity. High speed results in large centrifugal forces in discs and induces large stresses and deformations. Minimizing weight of such disks yields various benefits such as low dead weights and lower costs. In order to attain a certain and reliable analysis, disk with variable thickness and density is considered. Semi-analytical solutions for the elastic stress distribution in rotating annular disks with uniform and variable thicknesses and densities are obtained under plane stress assumption by authors in previous works. The optimum disk profile for minimum weight design is achieved by the KarushKuhn Tucker (KKT) optimality conditions. Inequality constrain equation is used in optimization to make sure that maximum von Mises stress is always less than yielding strength of the material of the disk.